Fuel burner safety control system



May 11, 1954 w. A. RAY

FUEL BURNER SAFETY CONTROL SYSTEM Filed March 17, 1950 FIG. 1.

I 21 fi W e M m M INVENTOR.

Patented May 11, 1954 UNITED STAT ics William A. Bay, North Hollywood, Calif., as-

signor to General Controls 00., a corporation of California Application March 17, 1950, Serial No. 150,198

3 Claims. 3

This invention relates to a thermocouple operated safety control system for gas or oil burners. Such a system is, for example, disclosed in a prior application, filed on December 14, 1948 under Serial. No. 65,113, now Patent No. 2,624,358, granted January 6, 1953, and entitled: Safety Control Fuel Valve.

This application is a continuation-in-part of an application, Serial No. 38,343, filed on July 12, 1948, in the of William A. Ray, now Patent No, 2,535 502, granted December 26, 1950, and entitled: Thermocouple for Gas or Oil Burners.

In many forms of gas burner systems, use is made of a thermoelectric generator influenced by the heat of the pilot flame, and arranged in an electric circuit to cause interruption in the supply of fuel in the event of pilot flame failure.

Such thermocouples are formed by joining two thermoelectrically dissimilar metals, such as iron and copper, or Copel and Chromel, and subjecting the junction to a temperature higher than that at the end junctions between these thermoelectric conductors and the leads. When the hot junction is heated, a minute electric power is generated in a well understood manner. The temperature differential between the hot and cold junctions determines the amount of power generated; the greater this differential, the greater the power.

This power, although minute, is utilized to maintain a definite control condition, such as to maintain a fuel valve open, for passing fuel to the burner. Upon pilot flame failure, the hot junction that had been subjected to the heat of the pilot flame cools; and, ultimately, the temperature differential is reduced to such an extent that the power generated is insufflcient to maintain the control for passing fuel to the burner. There is a consequent interruption to the flow of fuel, and the system is inactive, preventing escape of unignited fuel.

In the past, it has been common to insert the hot junction directly in the flame, the cold junc- -tions being exposed to the circumambient temperature of the furnace chamber or of the atmosphere. In such an arrangement an appreciable time must elapse before the junctions attain substantially equal temperature so as to interrupt the flow of fuel.

It is one of the objects of this invention to provide a simple and effective thermocouple systerm that insures a quicker response of the control system upon flame failure.

In order to accomplish this result, thethermocouple is so arranged that both the hot junction and the cold junction are inserted into the flame; and, although the flame temperature may be the same in the absence of the junctions, their presence results in a difference in temperature at the junctions sufficient to provide a controlling electromotive force. It is necessary that the temperature differential be only a few hundred degrees Fahrenheit. This difference is readily attained by proper choice and arrangement of the thermoelectric conductors. When the pilot flame fails, the hot and cold junctions reach equal temperatures, since then both junctions are subjected equally to the circumambient temperature of the furnace chamber.

The arrangement consists of three thermoelectric conductors serially joined to form two junction the end conductors having diflerent capacities to conduct heat away from the flame. That junction which is joined to the conductor which conducts heat faster has a materially lower temperature than the other junction. There are several ways in which this result may be effected.

It is accordingly another object of this invention to provide a control system using thermocouple structure in which both the hot and cold junctions may be placed in a flame, and yet in which there is generation of an adequate electromotive force for control purposes.

Thi invention possesses many other advantages, and has other objects which may be made more clearly apparent from a consideration of several forms in which it may be embodied. Such forms are shown in the drawings accompanying and forming part of the present specification. These forms will now be described in detail, illustrating the general principles of the invention; but it is to be understood that such detailed description is not to be taken in a limiting sense, since the scope of th invention is best defined by the appended claims.

Referring to the drawings:

Fi ure 1 is a schematic diagram of a control system embodying the invention;

Fig. 2 is an elevation of a thermocouple structure utilized in the invention shown in use in connection with a gas pilot burner, the scale of the figure being enlarged;

Fig. 3 is a sectional view, taken along a plane corresponding to line 3-t of Fig. 1; and

Fig. l is a view similar to Fig. 2 of a modified form of the invention.

In the system shown in Fig. l, a main burner i is shown as supplied with fuel from a conduit 2, through a safety valve structure 3, as well as through an electromagnetically operated valve 4.

The valve 3 is controlled by the aid of a control switch 5 that is included in series with the operating electromagnet of the valve 4, and which may respond to temperature variations, or the like. For example, the control switch 5 may he a thermostatically controlled apparatus.

A pilot flame burner E in the form of a tube is used for igniting the main burner 5 whenever the control switch 5 demands more heat. The system is shown as in inactive position. The pilot flame l, for that reason, is shown in dot-anddash lines, as well as the main burner flame 8.

By the aid the safety valve structure 3, the supply of fuel to the burners i and 6 is interrupted in the event of pilot flame failure. This safety valve structure 3 is diagrammatically illustrated, and is similar to that described in the said prior application, Serial No. 38,343. Thus, the valve ucture has an inlet chamber 9 closed by a movawall, such as a diaphragm 59. When the salety valve is open, fuel can pass to the electromagnetically operated valve he safety valve structure includes a plug valve, haw ing a man"; ierable plug 52 with a transverse p -e p g is rotatably seated in the body i 01 the safety valve 3. When the plug i2 rotated through ninety degrees in a clockwise direction, the port 53 becomes aligned with the port 55, as "l as with. aport 55, to permit passage of fuel to the valve 5.

A. safety valve closu'e is opmatively mounted in the chamber This includes a lever l' l having a pivot pin ll. The free end of the lever carries valve closure by the of a pivot pin i9. It cooperates with a raised seat around port ll.

An interlocking inechan'sm, similar to that shown in. pr or application, Serial No. 38,343, is arranged so that coun ell-clockwise movement of mg i2. will operate to lift the lever it in a clockwise direction to move the valve closure 18 away from its seat. At the same time, another lever 22?, connected to lever it, is moved to bring a disc armature into attracted position with respect to an electromagnet 22. The lifting mechanism is diagrammatically illustrated by a push rod 45 and an arm connected to the handle that rotates plug Since this invention is not concerned with the details of the safety valve structure and si es said prior application, lately describes this structui necessary.

The electi l of a coil 23 w ich i 3 from a thermocouple structure the heat of the pilot tame l. ampl If necessary, an r of desired form, may interposed sew-icon the structure 2- 5 and coil 23. When the pilot name '5 is in existence, the coil 23 is energized sufficiently to hold the armature Z! attracted position. erehy maintaining the safety valve closure is in open position. Upon pilot flame failure, the coil 23 is ale-energized, and the safety valve 3 returns to the closed position of Fig. l, and the armature 2! drops to the released position.

Although the power generated or controlled by electromagnet 2:3 is suilicient to hold the armature 2! in its attracted position, it may not be sufficient to attract the armature 2i from the released position of Fig. 1. Accordingly, it is necessary to reset the armature 22 to the attracted position and to hold it there while the pilot flame I is re-ignited.

In order to reset the mechanism, and as described in said prior application, Serial No. 38,343, the operator of plug l2 may be rotated in a counterclockwise direction for opening the safety valve closure 18 and for bringing the armature 2| into attracted position. During this resetting period, a slot or port 25 serves to connect port II with the conduit 25 leading to the pilot burner 6, so that the pilot burner flame can be ignited.

After a short time, the plug H: can be released and turned to open position in a clockwise direction.

The thermocouple structure 24 is illustrated most clearly in Figs. 2 and 3. It incorporates the end conductors 2'1 and 28 and an intermediate conductor 29. The intermediate conductor 29 is shown as Welded, fused, or otherwise joined, to end conductors 2'5 and 23 to form the junctions 38 and 3!. These conductors can he of 18 gauge wire of materials to be hereinafter referred to. The intermediate conductor 29 is quite short and is of the order of three-sixteenths of an inch lon The end conductors 2? and 28 may conveniently be clamped between two insulation blocks 32 appropriately grooved to conform to the conductors 2? and 28. These insulation blocks may he clamped together by the aid of bolts which pass through the end plate 34 and an extension 35 of a clamping bracket 36. This clamping bracket 38 surrounds the pilot burner tube 255 (which may be of the Bunsen type) for supporting the thermocouple structure.

Both junctions Bil and iii are placed in the pilot flame i above the inner cone 3?, which defines a cooler root portion of the flame. The points where these junctions 352 and 3! are located would have substantially the same temperature if the thermocouple junctions were out of the flame l. However, due to the structure now to be described, the temperature of junction 30 is maintained substantially lower than the temperature of junction 3!. In this way, a thermoelectric current is generated which may be utilized for the operation of the control system shown in Fig. 1. The end conductors 21 and 28 are joined, as by welding, to the copper conductors 3i and 39.

The end conductors 27 and 28 are made of material that is thermoelectrically different from the material of the intermediate conductor 29. Thus, for example, the end conductors 21 and 23 may be made of Copel and the intermediate conductor 2e 01" Chromel. Both of these materials are well known alloys suitable for thermocouple construction.

The junction 36 is maintained cooler than junction 3!, since the end conductor 21 which forms the junction 39 has a greater mass within the flame 1 than the other end conductor 28 which forms the junction 35. Accordingly, there is a greater heat conduction away from the junction 39 than from junction 3!. In other words, the cooling effect of conductor 21 is greater than the cooling effect of conductor 28.

Should the pilot flame i become extinguished, or fail, there is a very rapid equalization of temperature between the two thermocouple junctions 39 and 3!. This is due to the fact that the intermediate conductor 29 is short, and transfer of heat from hot junction 3! to cold junction 30 is quite rapid. Furthermore, the performance of the thermocouple structure is entirely independent of the temperature of the circumambient atmosphere.

Although the end conductors 21 and 28 have been described as made from the same material such as Copel, it it possible to obtain the same effects when different materials are used for these end conductors. Thus, the conductor 21 may be made from thermoelectric material which has better heat conductivity than con ductor such, for example, as platinum or: silver. This greater heat conductivity serves to lower the temperature of the junction 3% still further. In fact, under such circumstances, the length of the end conductors in the flame "i may even be the same; and yet one junction will be maintained at a lower temperature than the other.

This form is illustrated in Fig. 4. In this form the end conductor 45 is made of a material that has relatively high heat conductivity, such as platinum or silver. The other end conductor 3| may be made of Copel, and the intermediate conductor 52 may be made of Chromel to form the cold junction 33 and the hot junction M. As before, these junctions 53 and 44 are located in the main portion of the flame away from the inner cone 3?. The better heat conducting element it serves to reduce the temperature of the junction d3 substantially below that of the temperature of junction dd.

In use, it has been found that temperature differentials of the order of several hundred degrees Fahrenheit can be steadily maintained between the junctions. This is suflicient to produce the required electrical energy for control purposes.

The inventor claims:

1. In apparatus of the character described: a fuel burning device adapted to produce a flame having a cone; a movable member to be controlled; an electromagnet influencing the position of said member; and a thermocouple structure influenced by the heat of said flame for controlling said electromagnet and comprising: means forming a pair of thermoelectric junctions including two end conductors and an intermediate conductor, all three conductors being serially joined, said intermediate conductor being of a material thermoelectrically dissimilar to those of the end conductors, both junctions thus formed being disposed with respect to said fuel burning device such that upon existence of a flame at said device, the junctions are eated within the flame and substantially above said cone portion thereof, the lengths of the end conductors within the flame being unequal for producing a temperature difference between the said junctions large in comparison with the natural temperature gradient of the flame, and said end conductors having substantially identical cross sections.

2. In apparatus of the character described: a fuel burning device adapted to produce a flame; a movable member to be controlled; an electromagnet influencing the position of said member; a thermocouple structure influenced by the heat of said flame for controlling said electromagnet and comprising: two end conductors and 2 intermediate conductor, all three being serially joined to form a pair of thermoelectric junctions, said intermediate conductor being of a material thei'inoelectrically dissimilar to those of the end conductors, both junctions thus formed being inserted in said flame and located at points that would have substantially the same temperature if the junctions be removed from the flame, the lengths of the end conductors within the flame being unequal and having substantially identical cross sections.

3. In apparatus of the character described: a fuel burning device adapted to produce a flame; a movable member to be controlled; an eiectrcmagnet influencing the position of said member; and a thermocouple structure influenced by the heat of the flame for controlling said electromagnet and comprising: two end conductors and an intermediate conductor, all three conductors being serially joined to form a pair of thermoelectric junctions, said end conductors being of thermoelectrically similar materials, and said intermediate conductor being of a material thermoelectrically dissimilar to that of the end conductors, both junctions thus formed being inserted in the flame and located at points in the flame that would have substantially the same temperature if the junctions be removed from the flame, the cross sections of both end conductors being substantially identical, and the lengths of the end conductors within the flame being unequal.

References Cited in the file of this patent UNITED STATES PATENTS Number Name Date 1,863,373 Harrison June 14, 1932 2,311,785 Sparrow Feb. 1943 2,351,277 Mantz June 13, 1944: 2,370,326 Ray Feb. 2 1945 2,384,696 Ray Sept. 11, 1945 2,385,530 Paille Sept. 1945 

